A waterproofing membrane and a method of making the same

Abstract

This application relates to the field of building waterproof membrane technology, and discloses a waterproof membrane and its preparation method. The waterproof membrane of this application includes a base fabric layer, an adhesive coating layer, and a ketone vinyl ester resin layer; the adhesive coating layer is disposed on both sides of the base fabric layer, and the ketone vinyl ester resin layer is disposed on the surface of the adhesive coating layer; the base fabric layer is a woven / knitted hybrid fabric, the adhesive coating layer includes ethylene-vinyl acetate copolymer, dialkyl peroxide crosslinking agent, and silane coupling agent, and the ketone vinyl ester resin layer includes ketone vinyl ester, polyvinyl chloride, stabilizer, and soybean oil. This waterproof membrane differs from conventional polymer waterproof membranes in that it uses a woven / knitted hybrid fabric as the base fabric layer, and employs suitable adhesives and ketone vinyl ester resin to form a multi-layer composite structure through hot pressing technology. This allows both sides of the base fabric layer to have a waterproof system, combining excellent waterproof performance and mechanical properties. It is lightweight, thin, soft, and tough, not prone to peeling and leakage, and is convenient and efficient to construct.

Description

Technical Field

[0001] This application relates to the field of building waterproof membrane technology, specifically to a waterproof membrane and its preparation method. Background Technology

[0002] Existing polymer roll waterproofing systems employ a single-layer waterproofing system, using fiberglass or polyester nonwoven fabric as the base layer, or synthetic resin or synthetic rubber as the base material. Long-term contact with fiberglass can cause irritation to the respiratory tract, skin, and eyes, and may even increase the risk of cancer. Polyester nonwoven fabric has poor puncture resistance and tensile strength, resulting in poor overall mechanical properties, poor adhesion, and difficulty in achieving complete bonding with the substrate. Furthermore, the overall thickness of existing polymer roll waterproofing systems exceeds 3.5mm, leading to inconvenience in use and poor flexibility. Summary of the Invention

[0003] In view of this, the purpose of this application is to provide a waterproof membrane and its preparation method, so that the waterproof membrane can achieve a multi-layer composite structure with a thickness of 0.8-0.9mm, so that both sides of the base fabric layer have a waterproof system, which combines excellent waterproof performance and mechanical properties, and is lightweight and flexible overall.

[0004] To solve the aforementioned technical problems / achieve the aforementioned objectives, or at least partially solve the aforementioned technical problems / achieve the aforementioned objectives, as a first aspect of this application, a waterproof membrane is provided, comprising a base fabric layer, an adhesive coating layer, and a ketene vinyl ester resin layer; the adhesive coating layer is disposed on both sides of the base fabric layer, and the ketene vinyl ester resin layer is disposed on the surface of the adhesive coating layer; the base fabric layer is a woven / knitted mixed-structure fabric, the adhesive coating layer comprises ethylene-vinyl acetate copolymer, dialkyl peroxide crosslinking agent, and silane coupling agent, and the ketene vinyl ester resin layer comprises ketene vinyl ester, polyvinyl chloride, stabilizer, and soybean oil.

[0005] Optionally, the woven and knitted mixed structure fabric is woven by embedding warp and weft yarns into a warp-knitted structure based on polyester fibers.

[0006] Optionally, the adhesive coating comprises 80-94 wt.% ethylene-vinyl acetate copolymer, 5-8 wt.% dialkyl peroxide crosslinking agent and 1-2 wt.% silane coupling agent.

[0007] Further optionally, the dialkyl peroxide crosslinking agent is bis(2-diphenyl)-5-diphenyl ether, and the silane coupling agent is 3-aminopropyltriethoxysilane.

[0008] Optionally, the ketene vinyl ester resin layer comprises 31-45.5 wt.% ketene vinyl ester, 45.5-62 wt.% polyvinyl chloride, 3.5-4.5 wt.% calcium-zinc stabilizer, and 3.5-4.5 wt.% epoxidized soybean oil.

[0009] Further optionally, the mass ratio of ketone vinyl ester to polyvinyl chloride is ≥1:2, and the thickness of the ketone vinyl ester resin layer is 0.23-0.50 mm.

[0010] As a second aspect of this application, a method for preparing the aforementioned waterproof membrane is provided, comprising:

[0011] Step 1: Rinse the base fabric with acetone to remove surface organic impurities, dry it, and then impregnate it in the adhesive.

[0012] Step 2: The impregnated base fabric is rolled on a pressure roller and then dried;

[0013] Step 3: Place the ketone vinyl ester resin on the dried base fabric surface and calender it to obtain the waterproof membrane.

[0014] Optionally, the immersion time is 30-60 minutes.

[0015] Optionally, the drying temperature is 130-150℃ and the time is 40-60 minutes.

[0016] Optionally, the rolling temperature is 145-165°C and the rolling time is 120-180s.

[0017] The waterproof membrane of this application differs from conventional polymer waterproof membranes. It uses a woven and knitted mixed-structure fabric as the base layer, and employs suitable adhesives and vinyl ketone resin to form a multi-layer composite structure through hot pressing technology. This allows both sides of the base layer to have a waterproof system, combining excellent waterproof performance and mechanical properties. The overall structure is lightweight, thin, soft, and tough, and is not prone to peeling or leakage. It is convenient and efficient to construct. In addition to roof waterproofing systems, it also meets the requirements for outdoor ground waterproofing systems, underground waterproofing systems such as tunnels. Attached image description:

[0018] Figure 1 The diagram shows a process flow chart for preparing the waterproof membrane described in this application; A is a process flow chart for impregnating the adhesive coating solution; B is a process flow chart for bonding the woven / knitted blended fabric base layer and the adhesive; C is a structural diagram of the waterproof membrane; wherein, 1: bis(2,5) crosslinking agent; 2: 3-aminopropyltriethoxysilane; 3: ethylene-vinyl acetate copolymer; 4: adhesive; 5: base fabric layer; 6: adhesive coating; 7: pressure roller; 8: ketene vinyl ester resin layer;

[0019] Figure 2 The diagram shows a mixed woven and knitted fabric structure; 9: polyester fiber warp knitting, 10: polyester fiber warp yarn, 11: polyester fiber weft yarn. Detailed implementation method:

[0020] This application discloses a waterproof membrane and its preparation method. Those skilled in the art can refer to the content of this document and appropriately modify the process parameters to achieve the desired result. It should be particularly noted that all similar substitutions and modifications are obvious to those skilled in the art and are considered to be included in this application. The product and preparation method of this application have been described through preferred embodiments. Those skilled in the art can obviously make modifications or appropriate alterations and combinations to the product and preparation method described herein without departing from the content, spirit, and scope of this invention to realize and apply the technology of this invention.

[0021] In a first aspect of this application, a waterproof membrane is provided, comprising a base fabric layer 5, an adhesive coating layer 6, and a ketone vinyl ester resin layer 8; the adhesive coating layer 6 is disposed on the upper and lower surfaces of the base fabric layer, and the ketone vinyl ester resin layer 8 is disposed on the surface of the adhesive coating layer 6 away from the base fabric layer 5; a structural schematic diagram is shown below. Figure 1 -C.

[0022] The base fabric layer is a woven and knitted mixed structure fabric. This application uses a unique warp-knitted fabric, which is woven by embedding warp yarns 10 and weft yarns 11 into polyester fibers on the basis of the warp-knitted structure (polyester fiber warp knitting 9). See the schematic diagram. Figure 2 In some embodiments of this application, the warp and weft yarns of the base fabric layer are both made of 840×1000-900×1070D polyester fiber, and the warp-knitted yarns are made of 42×50-50×63D polyester fiber; the warp and weft density of the base fabric layer is 65-75 threads / 10cm, the thickness is 0.15-0.25mm, and the weight is 155-165g / m². 2 Currently, the common base material for polymer waterproof membranes is polyester nonwoven fabric or fiberglass cloth. The weight of the base material is 2.5 to 3 times that of the base fabric layer in this application. After processing, the thickness of the waterproof membrane in this application is 0.8 to 0.9 mm, while the thickness of the waterproof membrane made of polyester nonwoven fabric is 2.5 to 3.5 mm. The tensile strength of common polyester nonwoven fabric is 0.8 to 1 N / cm, while the tensile strength of the base fabric layer in this application can reach 2 to 3 N / cm.

[0023] The base fabric layer and the adhesive coating form a chemical molecular-level bond through an adhesive, giving the waterproof membrane strong integrity and superior bonding strength. This not only prevents interlayer peeling of the membrane in harsh environments but also prevents moisture from penetrating the membrane edges, thus avoiding weld delamination. In some embodiments of this application, the adhesive coating includes an ethylene-vinyl acetate copolymer, a dialkyl peroxide crosslinking agent, and a silane coupling agent.

[0024] In some embodiments of this application, the adhesive coating is formed by an adhesive, which is prepared by uniformly mixing and reacting an ethylene-vinyl acetate copolymer with a crosslinking agent and a silane coupling agent. This application compares the effects of using ethylene-vinyl acetate copolymer and acrylate respectively to prepare the adhesive. The results show that, compared with acrylate, the adhesive prepared by ethylene-vinyl acetate copolymer, after being bonded to the base fabric layer, has 15-16% higher tensile properties. In addition, it also performs better in terms of moisture permeability and loading rate.

[0025] In some embodiments of this application, the silane coupling agent is selected as 3-aminopropyltriethoxysilane. Common silane coupling agents also include KH-560, KH-570, VTMS, etc. Compared with these silane coupling agents, 3-aminopropyltriethoxysilane can significantly improve the tensile strength, flexural strength, and other mechanical properties of the base fabric layer.

[0026] In some embodiments of this application, the dialkyl peroxide crosslinking agent is bis(2,5-dialkyl)-5-dialkyl peroxide. Other common dialkyl peroxide crosslinking agents include DCP and BIPB. Compared with these crosslinking agents, bis(2,5-dialkyl)-5-dialkyl peroxide has excellent dispersibility, fast vulcanization speed, no volatility, and is more conducive to the formation of adhesive coating and effective adhesion between the base fabric layer and the ketone-vinyl resin layer.

[0027] In some embodiments of this application, the adhesive coating comprises 80-94 wt.% ethylene-vinyl acetate copolymer, 5-8 wt.% dialkyl peroxide crosslinking agent, and 1-2 wt.% silane coupling agent.

[0028] In some embodiments of this application, the ketene vinyl ester resin layer comprises 31-45.5 wt.% ketene vinyl ester, 45.5-62 wt.% polyvinyl chloride, 3.5-4.5 wt.% calcium-zinc stabilizer, and 3.5-4.5 wt.% epoxidized soybean oil. The ketene vinyl ester:polyvinyl chloride mass ratio is ≥1:2, and the ketene vinyl ester resin layer thickness is 0.23-0.50 mm. The ketene vinyl ester resin layer possesses excellent waterproof performance. Compared with other waterproof membranes, this surface layer not only has excellent environmentally friendly properties but also provides excellent UV resistance, chemical corrosion resistance, prevention of cracking or splitting, and long-term flexibility suitable for various climatic conditions. This long-term flexibility also extends the service life of the membrane and the possibility of subsequent repairs. Experimental tests in this application show that the peel strength of the ketene vinyl ester resin layer can reach 4.5-6 N / mm.

[0029] In a second aspect of this application, a method for preparing the aforementioned waterproof membrane is also provided, comprising:

[0030] Step 1: Rinse the base fabric with acetone to remove surface organic impurities, dry it, and then impregnate it in the adhesive.

[0031] Step 2: Roll the impregnated base fabric on the pressure rollers and then dry it;

[0032] Step 3: Place the ketone vinyl ester resin on the dried base fabric surface and calender it to obtain the waterproof roll material.

[0033] In some embodiments of this application, the immersion time is 30-60 minutes.

[0034] In some embodiments of this application, the drying temperature is 130-150°C, and the time is 40-60 minutes. The drying time and temperature after impregnation and padding alter the bonding effect between the adhesive and the woven / knitted blended fabric. Because the bis(2,5) crosslinking agent in the adhesive decomposes at high temperatures to generate peroxide free radicals, and the active hydrogen on the amino group of 3-aminopropyltriethoxysilane can tightly bind with the ethylene-vinyl acetate copolymer and the bis(2,5) crosslinking agent through chemical bonds, the drying temperature and time affect the reaction effect between the two and the ethylene-vinyl acetate copolymer. If the time is too short or the temperature is too low, the moisture in the adhesive will not completely evaporate and will remain in the base fabric layer, preventing the adhesive from forming a waterproof layer and thus affecting the waterproof performance of the roll material. Furthermore, the long aliphatic chains in the adhesive will not be fully crosslinked, affecting the hygroscopicity and permeability of the base fabric layer. If the time is too long or the temperature is too high, the ethylene-vinyl acetate copolymer will generate unsaturated polyolefin chromophores due to the presence of water molecules, and with the accumulation of unsaturated polyolefin compounds, the color of the adhesive coating gradually changes from light yellow to dark brown.

[0035] In some embodiments of this application, the rolling temperature is 145-165°C and the rolling time is 120-180s.

[0036] In the comparative experiments provided in this application, unless otherwise specified, all experimental conditions and materials remain consistent to ensure comparability. Furthermore, all materials used in this application are commercially available.

[0037] The following provides a further description of the waterproof membrane and its preparation method provided in this application.

[0038] Example 1:

[0039] A 92.5% ethylene-vinyl acetate copolymer solution was stirred in a high-speed mixer for 60-90 seconds. Simultaneously, 2% 3-aminopropyltriethoxysilane and 5.5% bis(2,5) crosslinking agent were added to obtain the adhesive for later use. The woven and knitted blended fabrics were repeatedly rinsed with acetone solution (according to...). Figure 2 The woven base fabric is dried and then immersed in the adhesive for 45 minutes.

[0040] After impregnating the woven / knitted blended fabric base with the adhesive, it is rolled on a pressure roller to coat each yarn with the adhesive and squeeze out excess solution. This rolling process is repeated 2-4 times. After rolling, the base fabric is placed in an oven to dry at 130-150℃ for 40-60 minutes.

[0041] The outermost layer of the waterproof membrane is a vinyl ketone resin layer. 31 wt.% vinyl ketone, 62 wt.% polyvinyl chloride, 3.5% calcium-zinc stabilizer, and 3.5% epoxidized soybean oil are granulated using a twin-screw extrusion method and then hot-pressed into a film. The vinyl ketone resin layer and the woven / knitted blended fabric base are then hot-pressed in a vulcanizing machine for 150 seconds at 155℃. During the calendering process, the thickness of the waterproof membrane is ensured to be uniform and maintained within the range of 0.8-0.9 mm, and both sides of the woven / knitted blended fabric base have a vinyl ketone resin layer.

[0042] The relevant mechanical performance indicators of the waterproof membrane of this application are shown in Table 1 after testing.

[0043] Table 1

[0044]

[0045] Experimental example:

[0046] Based on Example 1, different control waterproof membranes were prepared according to the following differences, while the rest remained the same as in Example 1, and their relevant mechanical properties were tested;

[0047] (1) A control waterproof membrane was prepared by replacing the high-density warp-knitted fabric of this application with polyester fiber nonwoven fabric. The relevant mechanical properties of the prepared control waterproof membrane are shown in Table 2 below.

[0048] Table 2

[0049]

[0050]

[0051] (2) Acrylic ester was used to replace the ethylene-vinyl acetate copolymer in the adhesive of this application to prepare a control waterproof membrane. The relevant mechanical properties of the prepared control waterproof membrane are shown in Table 3 below.

[0052] Table 3

[0053]

[0054] (3) Three control waterproof membranes were prepared by replacing 3-aminopropyltriethoxysilane in the adhesive of this application with KH-560, KH-570 and VTMS respectively. The relevant mechanical properties of the prepared control waterproof membranes are shown in Table 4 below.

[0055] Table 4

[0056]

[0057] (4) DCP and BIPB were used to replace the double 25 adhesive in this application in turn to prepare the control waterproof membrane. The relevant mechanical properties of the prepared control waterproof membrane are shown in Table 5 below.

[0058] Table 5

[0059]

[0060]

[0061] The comparative experiments in the above four aspects clearly show that replacing the constituent materials of the waterproof membrane with other conventional substances resulted in a decrease in maximum tensile strength, elongation at break, and seam peeling; at the same time, the replacement of certain substances also affected the thickness of the waterproof membrane.

[0062] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A waterproof membrane, characterized in that, The material comprises a base fabric layer, an adhesive coating layer, and a ketene vinyl ester resin layer; the adhesive coating layer is disposed on both sides of the base fabric layer, and the ketene vinyl ester resin layer is disposed on the surface of the adhesive coating layer; the base fabric layer is woven from polyester fibers embedded with warp and weft yarns on a warp-knitted structure; the adhesive coating layer comprises ethylene-vinyl acetate copolymer, a dialkyl peroxide crosslinking agent, and a silane coupling agent, wherein the dialkyl peroxide crosslinking agent is bis(2,5-dioxane) and the silane coupling agent is 3-aminopropyltriethoxysilane; the ketene vinyl ester resin layer comprises ketene vinyl ester, polyvinyl chloride, a stabilizer, and soybean oil.

2. The waterproof membrane according to claim 1, characterized in that, The adhesive coating comprises 82.2-94.3 wt.% ethylene-vinyl acetate copolymer, 2.8-14.1 wt.% dialkyl peroxide crosslinking agent, and 0.6-4.1 wt.% silane coupling agent.

3. The waterproof membrane according to claim 1, characterized in that, The ketene vinyl ester resin layer comprises 31-45.5 wt.% ketene vinyl ester, 45.5-62 wt.% polyvinyl chloride, 3.5-4.5 wt.% calcium-zinc stabilizer, and 3.5-4.5 wt.% epoxidized soybean oil.

4. The waterproof membrane according to claim 1 or 3, characterized in that, The mass ratio of ketone vinyl ester to polyvinyl chloride is ≥1:2, and the thickness of the ketone vinyl ester resin layer is 0.23-0.50 mm.

5. The method for preparing the waterproof membrane according to claim 1, characterized in that, include: Step 1: Rinse the base fabric with acetone to remove surface organic impurities, dry it, and then impregnate it in the adhesive. Step 2: The impregnated base fabric is rolled on a pressure roller and then dried; Step 3: Place the ketone vinyl ester resin on the dried base fabric surface and calender it to obtain the waterproof membrane.

6. The preparation method according to claim 5, characterized in that, The immersion time is 30-60 minutes.

7. The preparation method according to claim 5, characterized in that, The drying temperature is 130-150℃ and the time is 40-60 minutes.

8. The preparation method according to claim 5, characterized in that, The rolling temperature is 145-165℃, and the time is 120-180s.

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